Solar module system for metal shingled roof

ABSTRACT

A solar power system for a metal shingled roof, including: a plurality of metal roofing shingles; and a plurality of solar module mounting assemblies, wherein each of the solar module mounting assemblies has upper and lower module cleats that support upper and lower solar module frames thereon such that the upper and lower module frames are both spaced apart in a direction parallel to the roof, and spaced apart in a direction perpendicular to the roof.

PRIORITY APPLICATIONS

This application is a Continuation-In-Part of U.S. Utility patentapplication Ser. No. 17/393,959, entitled Solar Module System For MetalShingled Roof, filed Aug. 4, 2021, which claims priority to U.S.Provisional Patent Application 63/119,741 entitled Optimizing AndIntegrating Roofing And Solar For Labor, Cost, Safety, Aesthetics AndRapid Scaling, filed Dec. 1, 2020 and to U.S. Provisional PatentApplication 63/150,819 entitled Solar Integrated Roofing, filed Feb. 18,2021; the entire disclosures of which are incorporated herein byreference in their entireties for all purposes.

TECHNICAL FIELD

The present application relates to systems for mounting solar modules onmetal shingled roofs in particular and other roofs types in general.

BACKGROUND OF THE INVENTION

Various mounting approaches currently exist for placing solar modulesonto metal shingled roofs. Unfortunately, it has been quite difficult toquickly and easily determine the optimal positioning for the solarmodule mounts (which then support the solar modules thereon). Othercommon problems include accommodating thermal expansion and contractionof the modules, grounding both the metal shingles and the solar moduleframes, and preventing water intrusion between the shingles. Surfaceirregularities in the roof have also made it difficult to lay outaesthetically pleasing solar arrays.

What is instead needed is a system that facilitates quick and easyplacement of the solar mounting system onto the metal shingled roof. Aswill be shown, the present system provides an elegant solution to thisproblem, and to the other problems stated above.

SUMMARY OF THE INVENTION

The present system provides an integrated approach to quickly and easilymount solar panels onto a metal shingled roof. Preferred advantages ofthe present system may include any or all of the following:

-   -   (a) the metal roofing shingles are both dimensioned and marked        with index marks such that they can be used to position the        layout of the solar mounting assemblies thereon permitting a        rapid and easy system assembly on the roof. (As such, the        shingle positions act as templates for the solar module        positions);    -   (b) the markings on the metal roofing shingles can be used to        quickly and easily guide and align the position of successive        overlapping metal shingle rows thereover;    -   (c) the metal roofing shingles are grounded to one another in        both up and down directions on the roof and in lateral        directions across the roof;    -   (d) the solar modules are grounded to one another in both in up        and down directions on the roof and in lateral directions across        the roof;    -   (e) each of the solar module frames can freely thermally expand        and contract without any of the solar module frames pushing or        pulling on one another;    -   (f) successive solar modules appear to slightly overlap one        another in the up and down direction on the roof thus providing        a very aesthetically pleasing system that is well designed to        hide surface irregularities in the roof itself;    -   (g) the metal shingles can be made with capillary breaks therein        (either by forming lines into the shingles or by corrugating the        shingles) thus substantially reducing the problem of water        intrusion;    -   (h) the solar modules can be installed very quickly as each        mounting assembly simultaneously holds both an upper and a lower        solar module frame thereon;    -   (i) the solar module frames can be installed quickly using a        single tool positioned at the mounting assembly between the        upper and lower solar module frames; and    -   (j) the various retention clips provided to secure the solar        module frame to the mounting assemblies also provide grounding        of one solar module frame to another.    -   (k) the metal shingles can be installed very quickly as the        sidelaps do not require sliding in the lateral direction to fit        together;    -   (l) the metal shingles can be installed from either the left or        right side as the sidelaps do not require sliding in the lateral        direction to fit together; and    -   (m) the solar module mounting is conducted from the top of the        roof down to the bottom placing the functional elements in an        ergonomically preferred location between the operator's knees        and chest.

In one preferred aspect, the present system provides a solar powersystem for a metal shingled roof, comprising:

-   -   a plurality of metal roofing shingles; and    -   a plurality of solar module mounting assemblies that are        configured to be deck-mounted through the metal roofing shingles        into a roof (or alternatively mounted to the shingles themselves        without being deck mounted), wherein each of the solar module        mounting assemblies comprises:        -   a base,        -   an upper module cleat mounted onto the base, the upper            module cleat being configured to support a lower end of an            upper solar module frame, and        -   a lower module cleat mounted onto the base, the lower module            cleat being configured to support an upper end of a lower            solar module frame, and    -   wherein the upper and lower module cleat are configured to        support the upper and lower solar module frames such that the        upper and lower module frames are:        -   spaced apart in a direction parallel to the roof, and        -   spaced apart in a direction perpendicular to the roof.

Preferably, the metal roofing shingles are sized to be integer divisionsof the size of the solar module frames. For example, the metal roofingshingles can be sized to be ½ the width and ½ the height of the solarmodule frames to quickly facilitate module placement as will be shownherein. By correlating the size of the shingles to the size of the solarmodule frames, the present metal roofing shingles can be indexed todisplay locations for the positioning of the bases of the solar modulemounting assemblies thereon. In addition, the shingles can be marked orindexed to display locations for setting adjacent rows of overlappingshingles thereover. As such, each shingle can provide a template forpositioning another shingle and the shingles also can provide a templatefor positioning the solar module frames thereon.

In preferred aspects, the mounting assemblies each comprise upper andlower module cleats that permit expansion and contraction of the upperand lower module frames in up and down directions along the slope of theroof. In addition, both of the upper and lower module cleats can beattached to the base of the solar module mounting assemblies by a singlefastener that passes through a gap between the upper and lower moduleframes, thereby making system service, disassembly and reassembly fastand easy.

In preferred aspects, adjacent metal roofing shingles are electricallybonded to one another both in up and down directions along the slope ofthe roof, and laterally across the roof. This approach facilitates theuse of GFCI (Ground Fault Circuit Interrupters) which operate to switchoff the circuit, thus ensuring that any fault in the photovoltaic arraycan be shorted to the grounded shingle layer. Such an emergency shutdownsystem operates to protect emergency workers like firefighters.

In preferred aspects, the metal roofing shingles are non-planar suchthat drainage pathways form therebetween when the metal roofing shinglesoverlap one another. For example, the metal roofing shingles can becorrugated or have stamped lines formed therein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a plan view of the solar modules mounted onto a metalshingled roof, as viewed in a direction normal to the roof surface.

FIG. 1B is a front elevation view corresponding to FIG. 1A, as viewed ina horizontal direction parallel to the ground.

FIG. 2 is a view corresponding to FIGS. 1A and 1B, but with the solarmodules and mounting assemblies removed, showing how the positioning ofthe solar modules is determined by the position of the metal shingles.

FIG. 3 is a top perspective view of an exemplary metal shingle havingindex lines thereon for use with the present system.

FIG. 4 is a top perspective view showing the alignment of two adjacentmetal shingles using the index lines on the first metal shingle.

FIG. 5 is a top perspective view showing alignment of parallel rows ofmetal shingles using the index lines on the shingles.

FIG. 6 is a top perspective view of an alternate corrugated metalshingle for use in accordance with the present system.

FIG. 7 is a top perspective view of a pair of the corrugated metalshingles of FIG. 6, showing overlapping edges of the corrugatedshingles.

FIG. 8A is a top and perspective view of an alternate metal shinglehaving stamped wavy lines formed therein for providing capillary breaksfor use with the present system.

FIG. 8B is a top and perspective view of an alternate metal shinglehaving stamped straight lines formed therein for providing capillarybreaks for use with the present system.

FIG. 8C is a top plan view of an alternate metal shingle havingoverlapping raised portions near its edges to provide a block for winddriven rain, to protect the edge from being caught by ropes, shoes, orother installer activity, and it is a capillary break.

FIG. 8D is a perspective view of a pair of the shingles of FIG. 8Cshowing the overlap of one shingle onto another during assembly.

FIG. 9A is a side elevation view of the mounting assembly supporting anupper solar module frame and a lower solar module frame thereon.

FIG. 9B is a view corresponding to FIG. 9A, with one of the solarmodules removed showing further details of its frame.

FIG. 9C is a perspective view of the retaining and grounding clip ofFIGS. 9A and 9B.

FIG. 9D is a view similar to FIG. 9A, but instead using a singleretaining and grounding clip to connect to both the upper and lowersolar module frames.

FIG. 9E is a perspective view of the mounting assembly of FIG. 9D.

FIG. 9F is a top perspective view of the grounding clip of FIG. 9D.

FIG. 9G is a perspective view showing sealant added to the mountingassembly of FIG. 9D.

FIG. 9H is a bottom perspective view corresponding to FIG. 9G.

FIG. 9I is a side elevation view of an alternate mounting assembly.

FIG. 9J is a front perspective view of the mounting assembly of FIG. 9I.

FIG. 9K is a bottom perspective view of the mounting assembly of FIG.9I, showing an optional grounding element.

FIG. 9L is a side perspective view of the mounting assembly of FIG. 9I,showing an optional power electronics or micro-inverter mountingbracket.

FIGS. 9M to 9O are perspective views of an embodiment of the mountingassembly having a T-slot to attach an inverter thereto.

FIG. 9P is a perspective view of an alternate grounding clip.

FIG. 9Q is a side elevation view of the grounding clip of FIG. 9Pinstalled in a mounting assembly.

FIG. 9R is a perspective view of an alternate grounding clip.

FIG. 9S is a side elevation view of the grounding clip of FIG. 9Rinstalled in a mounting assembly.

FIG. 10A is a side elevation view of an alternate mounting assembly thatis mounted through a cut in a shingle to a bracket beneath the shingles.

FIG. 10B is a front perspective view corresponding to FIG. 10A.

FIG. 10C is a side perspective view corresponding to FIG. 10A, showingthe position of the mounting assembly with respect to the shingle.

FIG. 10D is a side elevation view of a mounting assembly positioned onthe edge of a shingle.

FIG. 10E is a side perspective view corresponding to FIG. 10D, showingthe position of the mounting assembly with respect to the shingle.

FIG. 10F is a perspective of the mounting clip of FIG. 10A.

FIG. 11A is a perspective view showing the placement of the lateralbonding clip between two adjacent solar module frames.

FIG. 11B is a side elevation view corresponding to FIG. 11A.

FIG. 11C is a side elevation view of an embodiment of the lateralbonding clip having a sharp grounding barb thereon.

FIG. 11D is a perspective view of the lateral bonding clip of FIGS. 11Ato 11C.

FIG. 11E is a perspective view of an alternate lateral bonding clip.

FIG. 11F is a side elevation view of the lateral bonding clip of FIG.11E.

FIG. 11G is a rear perspective view of the lateral bonding clip of FIGS.11E and 11F.

FIG. 11H is a perspective view of an alternate bonding clip.

FIG. 11I is a side elevation view of the bonding clip of FIG. 11H.

FIG. 12A is a perspective view of a pair of interlocking shingles.

FIG. 12B is a view corresponding to FIG. 12A, showing the overlappingand interlocking edges of the shingles.

FIG. 13A is a perspective view of a corrugated shingle having a pair ofgrounding barbs.

FIG. 13B is a close-up view of one of the grounding barbs.

FIG. 13C is similar to FIG. 13B, but the grounding barb is insteadunderneath the nail strip portion of the shingle.

FIG. 13D is a side elevation close-up view corresponding to FIG. 13C.

FIG. 14A illustrates three shingles with interlocking edges.

FIG. 14B illustrates a perspective view of the front sidelap interfaceof the three shingles of FIG. 14A.

FIG. 14C illustrates the assembly of the three shingles of FIGS. 14A and14B, showing a right-up hem and a left-down hem with a sidelap.

FIG. 15A is a perspective view of a plurality of optional firesuppression packets.

FIG. 15B is a perspective view showing an example of placement of thefire suppression packets of FIG. 15A.

FIG. 16 is a perspective view of an optional “under the shingle”mounting assembly.

FIG. 17A is a side elevation view of an optional inflatable system forpositioning a solar module (shown in a first position).

FIG. 17B corresponds to FIG. 17A, but the solar module has been liftedto a second position.

FIG. 18A is a perspective view of an alternate “under the shingle”mounting fastener.

FIG. 18B is a perspective view of the mounting fastener of FIG. 18Aattached to a metal shingle.

FIG. 18C is a side elevation view of the system of FIGS. 18A and 18B.

FIG. 19 is a side elevation view of a single ply roof integratedmounting cleat.

FIG. 20A is a perspective view of a building with a solar array thereonwith attic vents installed under the solar array.

FIG. 20B is a view corresponding to FIG. 20A, but with two solar modulesremoved so the attic vents can be seen.

FIG. 20C is a sectional side elevation view corresponding to FIG. 20A.

DETAILED DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B are views of the solar modules mounted onto a metalshingled roof, and FIG. 2 is a similar view but with the solar modulesand mounting assemblies removed, showing how the positioning of thesolar modules is determined by the position of the metal shingles.

Specifically, a roof of a building is covered by successive rows ofmetal shingles 10. As is standard with all shingles, the shingles arefirst placed down onto the roof with successive shingle rows overlappingone another. As is also standard, shingle placement is done from thebottom to the top of a slanted roof. Specifically, a first row ofshingles is laid down extending laterally across the bottom edge of theroof. A second row of shingles is then laid down thereover with thebottom edges of the second row on top of the top edges of the first row.This procedure is then carried out as successive shingle rows are laiddown with the workers eventually reaching the top edge of the roof.

Once the roofing shingles are in place, then solar module frames 20 aremounted to the roof on top of the shingles. Again, this is a commonprocedure, and the solar module frames 20 are typically installed withthe workers working down from the top of the roof to the bottom of theroof. The method of having the solar modules 20 installed from the topto the bottom of the roof is ergonomically preferred since it affordsthe installers the opportunity to secure the modules and do wiremanagement at a location between the installers' feet and chest. Inaccordance with the present system, however, several new and inventivefeatures and approaches are provided to both speed up and simplifysystem installation from what other systems had achieved in the past, asfollows.

First, the present shingles 10 are preferably dimensioned to be integerdivisions or integer multiples of the solar module frames 20. Forexample, metal roofing shingles 10 can be sized to be ½ the width and ½the height of the solar module frames 20. As such, the present systemwill be assembled with the solar modules positioned at preciselyrepeating locations on the roof. This is best understood by alsoreferring to FIG. 2 which shows distances D1 and D2. Specifically,Distance D1 is the width of a solar module frame 20. Distance D1 is alsothe distance across two metal shingles 10 (Note: the dotted lines on theshingles show the lateral side-to-side overlap across a row of shingles10, as will be further explained).

As can be seen, once the metal shingles 10 have been installed on theroof, the shingle positions themselves can be used to position the solarmodule frames 20 thereon. Simply put, there is a direct dimensionalrelationship between the size of the shingles 10 and the size of thesolar module frames 20. As such, the shingles 10 serve as a template forpositioning the mounting assemblies of the solar module frames 20 ontothe roof.

Returning to FIG. 1A, the present mounting assemblies (40 in FIGS. 9A,9B, 9D, 10A and 10B) can be located at positions 50. Exemplary positions50 are shown here as being at locations 25% and 75% of the distancealong the sides of the module frames. This represents an ideal placementas it minimizes cantilever effects across the width of the solar moduleframe. By using two mounting assemblies on the top and bottom sides ofthe solar module frames 20 as shown (one at 25% of the length of thesolar module frame and the other at 75% of the length of the solarmodule frame), an appropriate balance between providing support to thecenter and free edges of the solar module frame is achieved. Importantlyas well, in this particular layout, only two mounting assemblies 40 arerequired for supporting the top and bottom edges of each solar moduleframe 20. Additionally, all of the mounting elements are spaced at evenintervals across the roof equal to 50% of the length of a module.

As will be further explained, mounting assemblies 40 also providegrounding between the upper and lower solar module frames 20 that eachmounting assembly 40 supports. In addition, lateral bonding clips (60 inFIGS. 11A to 11D) can be positioned at locations 55. As will beexplained, lateral bonding clips 60 provide both stability between solarmodule frames 20 that are mounted side-to-side across the roof, and alsoprovide grounding between these adjacent solar module frames 20. As canbe seen, mounting assemblies 40 provide grounding between solar moduleframes 20 in the up-and-down direction on the roof. At the same time,lateral bonding clips 60 provide grounding between solar module frames20 in the lateral (side-to-side) direction. As such, all of the moduleframes 20 in the array can be grounded to one another.

In optional embodiments, GFCI (Ground Fault Circuit Interrupters) can beadded to the PV array. GFCIs operate to switch off the circuit, thusensuring that any fault in the photovoltaic array can be shorted to thegrounded shingle layer. Such an emergency shutdown system operates toprotect emergency workers like firefighters.

FIG. 3 illustrates an exemplary metal shingle 10. Shingle 10 has a nailstrip 11 at its top end. Importantly, shingle 11 also has index marks 12thereon. In this particular illustration, index marks 12 extend from thetop to the bottom of the shingle. It is to be understood that otherindexing mark configurations and designs may instead be used, allkeeping within the scope of the present invention. Index marks 12 may bepainted or inked onto shingles 10. Index marks 12 may also comprisegrooves formed or cut into the shingle (in which case, such groovescould also provide capillary breaks and thus fight water intrusion aswill be shown below). Additional index marks may also be provided, asdesired. Nail strip 11 may also have index marks printed thereon. Theoptional index marks on nail strip 11 may be used to position mountingassemblies 40 and the index marks running up and down the face of theshingle (as illustrated) may be used to position laterally adjacentshingles, as follows.

Referring to FIG. 4, a first shingle 10A is nailed into position. Next,a second shingle 10B is laid down next to 10A. As can be seen, the rightside edge of shingle 10B can be aligned with the leftmost index mark 12on shingle 10A. This approach provides a rapid way of positioning oneshingle after another across a lateral row of shingles even though theedge of the adjacent shingle 10B overlaps that of shingle 10A. Turningnext to FIG. 5, the indexing marks 12 on the shingles 10 can be usedboth to position laterally adjacent shingles in a row of shingles andalso to position a second row of shingles. Specifically, shingle 10A isfirst affixed to the roof. Next, shingle 10B is placed next to 10A withthe right side edge of shingle 10B aligned with the leftmost index mark12 on shingle 10A. Shingle 10C follows shingle 10B. Next, a new row isstarted with shingle 10D. As can be seen, shingle 10D can also bealigned with shingles 10A and 10B simply by aligning index marks 12 onthe various shingles. Next, shingle 10E is placed adjacent to shingle10D, etc.

Importantly, it is to be understood that the use of indexing marks 12can be used to provide an aligned array of shingles covering a roofsurface. As can also be seen, such alignment can easily be accomplishedboth in a lateral (i.e.: side-to-side across the roof) direction and inthe perpendicular (up-and-down the roof) direction. Using the presentindex marked shingles, shingle installation is fast and easy.

A second benefit of the present index marked shingles is that they canbe used to guide the placement of the mounting assemblies 40.Specifically, once the shingles have been placed on the roof in theiraligned orientations, the mounting assemblies 40 can be positionedthereon. This is due to the fact that the present shingles 10 arepreferably sized to correspond to the sizes of the solar module framesas explained above. For example, when the widths of the shingles arehalf of the width of the solar module frames, then every second shinglein a row will have a mounting assembly 40 positioned thereon at the samelocation on the shingle. As such, the position of shingles 10conveniently set forth the positions of mounting assemblies 40 thereon.As a result, the various index marks on shingles 10 can be used toensure spacing gaps between module frames 20 is consistent.

FIG. 6 shows an alternate exemplary shingle 10 for use in accordancewith the present system. Shingle 100 is similar in dimensions to shingle10. Shingle 100, however, has a surface which is corrugated (i.e.: ithas a series of raised and lowered portions thereon). In furtheroptional embodiments, the corrugated shingles may even be disposed in alarge roll that is unwound onto the roof. Stamped dimples 112 can beused similar to the index marks 12 of shingle 10 when aligning theshingles in a lateral row. For example, the rightmost end of anothershingle can be placed over the left edge of the shingle of FIG. 6, withits rightmost end aligned with the leftmost dimple 112 on the (bottom)shingle.

As best seen in FIG. 7, having the ends of shingles 100 overlay oneanother as shown in region 115 provides a series of capillary breaksbetween the shingles, thereby counteracting the effects of moistureintrusion. In various optional embodiments, long corrugated shinglesections can be provided such that they can be rolled out onto the roof.

FIG. 8A is a top and perspective view of an alternate metal shingle 10having stamped wavy lines 13A formed therein for providing capillarybreaks for use with the present system. Specifically, a capillary breakis formed when similar shingles are stacked one over top of another.Similarly, FIG. 8B is a top and perspective view of an alternate metalshingle 10 having stamped straight lines 13B formed therein forproviding capillary breaks for use with the present system.

FIG. 8C is a top plan view of an alternate metal shingle 110 havingoverlapping raised portions 113 near its edges to provide an aestheticand mechanical edge cover. Specifically, as seen in FIG. 8D, a pair ofshingles 110 are placed one over top of the other at their respectiveedges, providing protection to the cantilevered free edge of theuppermost shingle. The raised portions 113 in FIGS. 8C and 8D are formanaging the overlapped edges to avoid an aesthetic issue of one edgepopping up, and to avoid the top most edge from getting snagged byropes, shoes or other installer activity.

FIGS. 9A through 9S show further details of the preferred mountingassemblies 40 which support solar module frames 20 thereon. Taken alltogether, the present system provides a solar power system for a metalshingled roof, comprising: a plurality of metal roofing shingles 10; anda plurality of solar module mounting assemblies 40. Solar Modulemounting assemblies 40 are preferably configured to be deck-mountedthrough the metal roofing shingles into a roof, although other optionsare also contemplated (for example, simply attaching to the metalshingles 10), all keeping within the scope of the present system.

As seen in FIGS. 9A to 9E, solar Module mounting assemblies 40preferably each comprise a base 42, an upper module cleat 44 mountedonto base 42, the upper module cleat 44 being configured to support alower end of an upper solar module frame 20, and a lower module cleat 46mounted onto base 42, the lower module cleat 46 being configured tosupport an upper end of a lower solar module frame 20.

The upper and lower module cleats 44 and 46 are preferably configured tosupport the upper and lower solar module frames such that the upper andlower module frames are both: (a) spaced apart a distance D3 (runninggenerally parallel to the surface of the roof), and (b) spaced apart adistance D4 (running generally perpendicular to the roof). Each of thesetwo spacings or gaps provide unique advantages to the present roofingsystem, as follows.

First, the distance gap or spacing in direction D3 provides each ofupper and lower cleats 44 and 46 with space to flex as solar moduleframes 20 thermally expand or contract. Specifically, when module frames20 become heated and expand, cleats 44 and 46 can flex slightly towardsone another to accommodate this expansion. Conversely, when moduleframes 20 cool off and contract, cleats 44 and 46 can flex away from oneanother to accommodate this contraction. The benefit of the present gapor spacing in distance D3 is that the thermal expansion and contractionof any one module does not affect the surrounding module frames.Importantly, since the sides of the modules frames 20 are always heldslightly apart from one another (by distance D3), they never touch. Thisis a fundamentally different approach from many existing solar systemsin which the expansion and contraction of one module frame simply causesit to push against or pull away from an adjoining module frame. Anotherbenefit of the gap in distance D3 is that it permits access from abovefor a single tool (to affix screw or bolt 47) to be inserted andtightened (to simultaneously hold cleats 44 and 46 into position).

Second, the preferred spacing in direction D4 ensures that the two solarmodule frames 20 held by mounting assembly 40 are slightly offset fromone another and do not share the exact same plane. The advantage of thismounting technique provides the illusion that the solar modules aresomewhat overlapping to look like shingles themselves. The aestheticbenefit of this is somewhat counterintuitive. Specifically, it has beendifficult to provide a completely planar solar array on many buildingsdue to the fact that the roof itself is seldom completely planar.Instead, roofs tend to have irregularities where they stick up a bit toomuch in one place and other irregularities where they tend to sag down abit too much in another area. Attempting to place a planar array ofsolar modules onto a roof that is not truly planar itself has been verytime consuming in the past. Moreover, small adjustments in moduleplacement can have surprisingly large visual effects. This forcesinstallers to spend an inordinate amount of time raising and loweringthe sides and ends of the solar modules to achieve the right look.However, with the present system, all of this problem is completelyavoided. Instead, it is the intention of the present system to have thesolar modules 20 appear somewhat staggered in height (by distance D4).This makes alignment much faster and easier. These small differences inthe heights of the modules in a direction perpendicular to the roof(i.e.: distance D4) ideally camouflages irregularities in the roofitself.

As seen in FIGS. 9A, 9B and 9C, the solar module frames 20 can be heldsecurely in place by grounding clips 43. As seen in FIG. 9C, groundingclips 43 can have a small hook or barb 45 that scrapes into the anodizedframe of modules 20, thereby establishing electrical contact with themodule frame. As such, a grounding path is provided from the uppermodule frame 20 through its grounding clip 43, upper cleat 44, lowercleat 46, grounding clip 43 and into the lower module frame 20. FIGS. 9Dto 9F show an alternate grounding clip 43B connecting both the upper andlower module frames. In this embodiment, grounding clip 43B preferablyhas a large hole therein providing tool access to bolt or screw 47below. Grounding clip 43B provides direct grounding between the twomodule frames 20 (rather than relying on the grounding path goingthrough cleats 44 and 46 as in the case of a pair of grounding clips43). Another advantage common both to grounding clips 43 and 43B is thatthe direction of the barb 45 allows for frame movement up-and-down inthe direction along the roof, but also constrains lateral motion of theframes 20.

FIG. 9G shows a sealant injected through holes 49 to seal mountingassembly 40 onto the roof. FIG. 9H shows a bottom cavity 47 on each“leg” of base 42. Bottom cavity 47 can be used to place the sealanttherein (such as a butyl pad, silicone, asphalt, etc.) to assist insecuring mounting assembly 40 onto the roof. Screw holes 48 may bepositioned above cavity 47 on the two legs of mounting assembly 40.Screws passing through holes 48 (and cavity 47 below which is filledwith sealant) can be used to deck mount the mounting assembly throughthe metal shingles 10 directly onto the roof. In alternate embodiments,the mounting assembly 40 may be secured only to the shingles, and not tothe roof deck below. It is to be understood that the present systemencompasses both of these possibilities in mounting.

FIGS. 9I to 9L show an alternate mounting assembly 400 having a firstcleat 446 and a second cleat 444 operating similar to mounting cleats 46and 44 described above. An optional grounding element 430 is providedboth for grounding and for module retention. Lastly, in FIG. 9L anoptional support bracket 432 is provided for supporting powerelectronics, microinverters, rapid shutdown devices or similaraccessories.

FIGS. 9M to 9O are perspective views of an embodiment of the mountingassembly where cleats 446A and 44A each have a T-slot 447 to attach aninverter 449 thereto.

FIG. 9P is a perspective view of an alternate grounding clip 43C andFIG. 9Q is a side elevation view of the grounding clip 43C installed ina mounting assembly. Clip 43C has a flexible portion 45C, a bond cutter47C and bonding springs 48C. Grounding clip 43C's flexible portion 45Cpermits flexing during installation such that the modules 20 do notsmash into the mounting assembly. Flexible portions 48C assist inproperly locating and positioning the side edges of modules 20.

FIG. 9R is a perspective view of an alternate grounding clip 43D havinga barb 45D that scrapes into the anodized frame of modules 20, therebyestablishing electrical contact with the module frame. Flexible portions48D assist in properly locating and positioning the side edges ofmodules 20. FIG. 9S is a side elevation view of the grounding clip ofFIG. 9R installed in a mounting assembly.

FIG. 10A is a side elevation view of an alternate mounting assembly 40Bthat is mounted through a cut in a shingle 10 to a bracket beneath theshingles. The side perspective view of FIG. 10C shows the position ofthe mounting assembly 40B with respect to the shingle. As seen in FIG.10B, a bracket 41 is provided. Bracket 41 mounts to the roof deck andcomes up through either a pre-cut or hand-cut hole in shingle 10, orfits within the overlapping shingles with no cuts at all. Portions ofthe upper and lower edges of successive shingles can be wrapped aroundbracket 41, thereby providing alternatives to screwing through the metalshingle. This enables a sturdy mounting point that is concealed withinthe shingles for mounting the solar array. In addition, bracket 41provides grounding up and down the metal shingle array. Specifically,mounting assembly 40B holds the overlapping top and bottom edges of themetal roofing shingles 10. As such, mounting assembly 40B not onlygrounds the shingles to one another, but it also grounds the moduleframes 20 to one another. As such, the shingles and the module framescan all be grounded to one another.

FIGS. 10D and 10E show mounting assembly 40B positioned on the edge of ashingle. FIG. 10F is a perspective of the mounting clip 43 of FIG. 10A.The assembly shown in FIG. 10D has the advantage that it may clampdirectly onto the shingles with no intermediate bracket 41 if desired.

FIGS. 11A to 11D show the placement of the lateral bonding clip 60between two adjacent solar module frames 20. Each lateral bonding clip60 is dimensioned to hold laterally adjacent solar module frames 20 inalignment with one another while maintaining electrical conductivitybetween the laterally adjacent solar module frames. Preferably, thelateral bonding clip 60 has a pair of grounding barbs 61 thereon. Onegrounding barb 61 will make electrical contact with one of module frames20 in FIG. 11A, and the other grounding barb 61 will make electricalcontact with the other of module frames 20 in FIG. 11A.

FIGS. 11E to 11G are views of an alternate lateral bonding clip 60B.Lateral bonding clip 60B has flexible portions 61B in which groundingbarbs 62B are mounted. This bonding clip 60B is shaped to accommodatethermal expansion and contraction. In various optional embodiments, thebounding clip may be formed with an optional wire management channel65B.

FIGS. 11H and 11I are views of an alternate two-piece bonding clip 60C.Bonding clip 60C is formed from a member 61C (which may optionally be analuminum extrusion), and two clips 62C. Clips 62C preferably slide withthermal expansion and contraction such that they scratch through the PVmodule frame anodization.

FIGS. 12A and 12B are perspective views of a pair of adjacent shingles200 having overlapping edges, one with a feature such as a hem to createa space for water to drain out 210. Overlapping side edges 210 provideresistance to wind driven rain and enable fast installation.

FIGS. 13A and 13B are views of a corrugated shingle 100 having a pair ofgrounding barbs 105. FIG. 13C is similar to FIG. 13B, but the groundingbarb 105 is instead underneath the nail strip portion 11 of the shingle.FIG. 13D illustrates how grounding barb 105 makes electrical contactbetween upper and lower shingles 10, thereby providing top to bottomgrounding of the metal shingles on the roof.

FIG. 14A illustrates three shingles 300 with interlocking edges. FIG.14B illustrates a perspective view of the front sidelap interface of thethree shingles of FIG. 14A. FIG. 14C illustrates the assembly of thethree shingles of FIGS. 14A and 14B, showing a right-up hem and aleft-down hem with a sidelap. In accordance with this aspect of thepresent system, two of the shingles correspond to the down-roof edge(left), and one corresponds to the up-roof edge. In accordance with thepresent system, the hems of the shingles are sized in order to capturethe upper cleat of the two lower shingles which are not colinear.

FIGS. 15A and 15B show a plurality of optional fire suppression packets400. Preferably, fire suppression packets 400 are manufactured in ashort roll as illustrated. Packets 400 have a nail able area 401.Packets 400 are preferably placed under shingles 10 and may bestrategically positioned over weak spots such as over gaps betweenplywood. Packets 400 may optionally be made from a polymer film (TPO,polyethylene, EPDM, etc.) with pockets (like bubble wrap, etc.) filledwith a fire suppressant material such as magnesium hydroxide or ferroussulfate heptahydrate, or they may be a solid composite of co extrudedpolymer and fire suppression material.

FIG. 16 is a perspective view of an optional “under the shingle”mounting assembly 500. Mounting assembly 500 has a member 501 that isattached to clips 502. Clips 502 have edges (not shown) that arereceived under metal shingles 10. As such, the present system canprovide a mounting assembly 500 that does not require penetrations bemade through shingles 10. Member 501 is preferably a C-shaped channelthat provides munting flexibility in the up-down direction on the roof.Member 501 can be as short as a single shingle height, or alternatelyspan across the lengths of several shingle lengths.

FIG. 17A is a side elevation view of an optional inflatable system forpositioning a solar module (shown in a first position). FIG. 17Bcorresponds to FIG. 17A, but the solar module has been lifted to asecond position. In this optional aspect of the present system,inflatable tubes 602 and 604 are mounted under PV module 20. Preferably,inflatable tubes 602 and 604 are made of a flexible material such as TPOor EPDM. By inflating (or deflating with air or a hydraulic fluid) tubes602 and 604, the direction in which PV module 20 faces can be changed.For example, tube 602 can be inflated (FIG. 17B) such that PV module 20better faces the sun S. Another advantage of inflatable tube 602 and 604is that they provide cushioning support in the advent of hail.

FIGS. 18A to 18C illustrate an alternate “under the shingle” mountingfastener 700 which is attached to a shingle 10 with its flattened end701 received under the edge of one of the shingles 10.

FIG. 19 is a side elevation view of a single ply roof integratedmounting cleat system 800. Specifically, a cleat is pre-attached orfield attached to the TPO, EPDM, or other single ply roof membrane. Theframe 20 is then slipped onto the cleat. Optionally, the cleats can beintegrated into the rolls of roofing material (e.g.: TPO or EPDM) priorto install. The roofing material is then rolled out, welded at theseams, fastened per typical means, and solar panels are dropped on topand clipped into place. Metal clips may be riveted on, sewn in, orcaptured between two welded pieces.

FIGS. 20A to 20C show a building with a solar array thereon with atticvents 902 and 904 installed under the solar array. Attic fans 906 can bepositioned adjacent to vents 902 and 904 as shown. A control system 908operates fans 906. Control system 908 preferably also includestemperature and humidity sensing capabilities. A phase change ordesiccant material 910 can optionally be positioned adjacent to fans906. The desiccant material may optionally be MgSO4, or any othersuitable material. In operation, fans 906 and be operated to pull airinto the building attic or to push building air out of the attic throughvents 902 and 904. As such, fans 906 can preferably be operated to passair in both directions. The advantage of fans 906 is that they canassist in heating the building by pulling in outside air warmed by thePV array. Conversely, fans 906 can be used to cool the building bypushing warm attic air out of the building and across the underside ofthe PV array. An additional vent 908 permits moisture and temperaturemanagement of the building envelope. Fans 906 are preferablyindependently operable and reversible. Being reversible, fans 906 canselectively either bring in or expel building heat. The optional phasechange material 910 can act as a thermal reservoir to manage solar andbuilding envelope conditions. As such, the PV array itself operates as aheat pump for the building envelope. In optional approaches, when thetemperature of PV and the attic are high and the moisture capacity ofdesiccant 910 is high, the present system will draw air from attic andblow it across the PV modules in order to reduce their temperatures.

What is claimed is:
 1. A solar power system for a metal shingled roof,comprising: a plurality of metal roofing shingles; and a plurality ofsolar module mounting assemblies, wherein each of the solar modulemounting assemblies comprises: a base, an upper module cleat mountedonto the base, the upper module cleat being configured to support alower end of an upper solar module frame, and a lower module cleatmounted onto the base, the lower module cleat being configured tosupport an upper end of a lower solar module frame, and wherein theupper and lower module cleat are configured to support the upper andlower solar module frames such that the upper and lower module framesare: spaced apart in a direction parallel to the roof, and spaced apartin a direction perpendicular to the roof.
 2. The system of claim 1,wherein the metal roofing shingles are sized to be integer divisions ofthe size of the solar module frames.
 3. The system of claim 2, whereinthe metal roofing shingles are sized to be ½ the width and ½ the heightof the solar module frames.
 4. The system of claim 2, wherein the metalroofing shingles are indexed to display locations for the positioning ofthe bases of the solar module mounting assemblies thereon.
 5. The systemof claim 1, wherein the metal roofing shingles are indexed to displaylocations for setting adjacent rows of shingles thereover.
 6. The systemof claim 5, wherein the metal roofing shingles are indexed with linesextending from the top to the bottom of the shingle for aligning anoverlapping shingle row thereover.
 7. The system of claim 1, wherein theupper and lower module cleats flex to permit expansion and contractionof the upper and lower module frames in an up and down direction alongthe slope of the roof.
 8. The system of claim 1, wherein the upper andlower module cleats are attached to the base of the solar modulemounting assemblies by a fastener that passes through a gap between theupper and lower module frames when the upper and lower module frames arespaced apart in the up and down direction parallel to the slope of theroof.
 9. The system of claim 1, wherein the solar module mountingassemblies further comprise grounding clips touching each of the upperand lower module cleats thereby grounding the upper and lower solarmodule frames to one another.
 10. The system of claim 1, furthercomprising: a plurality of lateral bonding clips, each lateral bondingclip dimensioned to hold laterally adjacent solar module frames inalignment with one another while maintaining electrical conductivitybetween the laterally adjacent solar module frames.
 11. The system ofclaim 1, wherein adjacent metal roofing shingles are electrically bondedto one another both in an up and down direction along the slope of theroof, and laterally across the roof.
 12. The system of claim 1, whereinthe metal roofing shingles are non-planar such that drainage pathwaysform therebetween when the metal roofing shingles overlap one another.13. The system of claim 11, wherein: the metal roofing shingles arecorrugated, or the metal roofing shingles have stamped lines formedtherein.
 14. The system of claim 1, wherein the metal shingles each havenon-interlocking side edges.
 15. The system of claim 1, wherein themetal roofing shingles have side edges that are curved thereunder. 16.The system of claim 11, wherein the adjacent metal roofing shingles areelectrically bonded to one another with top and bottom edges of themetal roofing shingles overlapping and wrapping around one another. 17.The system of claim 16, wherein the overlapping top and bottom edges ofthe metal roofing shingles are used to secure the solar module mountingassemblies.